Sheet metal prong forming apparatus



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INVENTOR 2 Sheets-Sheet 1 C. B. BAILEY Aug. l0, 1937.

SHEET METAL PRONG FORMING APPARATUS Original Filed Aug. 24, 1931 Aug. 10, 1937. c. B. BAILEY SHEET METAL PONG FORMING APPARATUS Original Filed Aug. 24, 1931 2 Shee'l'.S-SheefI 2 "kai Patented Aug. 10, 1937 UNITED STATES PATENT OFFICE SHEET METAL PRONG FORMING APPARATUS of Maine Original application August 24, 1931, Serial No.

558,856, now Patent No. 2,019,474.

Divided and this application June 26, 1933, Serial No.

1 Claim.

This invention relates to an apparatus for making perforated and pronged sheets to be used in composite sheets for gasket, packing and other purposes in accordance with the method described and claimed in the Claude B. Bailey application, Serial No. 558,856, filed August 24, 1931, and of which this present application is a division.

The composite sheet in which the pronged and perforated sheet, produced by the apparatus, is to be used is composed of layers of non-metallic and metallic sheet material, such as asbestos and steel, with prongs or projections struck out of the metal layer or layers and extending into or embedded in the non-metallic layers for securing or anchoring the layers together in co-extensive and overlapping relation.

The perforating and prong forming apparatus is a part of a larger assembly in which the layers making up the composite sheet are fed into the assembled relation desired from a source of supply and then pressed together at the pressure required for their intimate connection in one continuous and uninterrupted operation.

The invention of this application relatesto the cutters, spacers and strippers of the prong producing part oi' the apparatus, and consists further in the matters hereinafter described and claimed.

In the accompanying drawings- Fig. l is a diagrammaticl view of the apparatus incorporating the invention;

Fig. 2 is an enlarged longitudinal sectional view of the layer guide and separator employed in the apparatus;

Fig. 3 isa perspective view, with one of the layers broken away, of the composite sheet produced by the apparatus of the invention;

Fig. 4 illustrates the action of one of the cutters in that part of the apparatus where prongs are provided on the metal layer;

Fig. 5 is a longitudinal sectional view taken on' line 5-5 of Fig. 4;

Fig. 6 is a similar sectional view illustrating how the metal layer is supported while being provided with prongs;

Fig. '7 is a top plane view of a group of strippers to be hereinafter described;

Fig. 8 is a view of the strippers taken on line 8 8 of Fig. 7;

Fig. 9 is a perspective view of one ofthe strip pers; and

Fig. 10 is a diagrammatic view of a form of feed to be hereinafter described. y

.. 'Ihe composite sheet ofr Fig. 3 produced bythe apparatus comprises three layers, two outer layers I, l of non-metallic sheet material, such as asbestos, and an intermediate layer 2 of sheet metal, such as sheet steel. The layers are coextensive, overlap and are anchored or secured together by prongs or projections 3, 3 struck out of the metal layer extending into the non-metallic layers. The prongs 3 are long enough to have their outer ends bent into clinching relation with the non-metallic layers when the layers are pressed together in the production of the composite sheet. The outer layers l being of yieldable material provide the cushion and seal required for the sheet when used for gasket and packing purposes. Moreover, the layers l being of asbestos, enables the sheet to pack joints subject to high temperatures, as encountered in the automotive and steam elds. In place of asbestos, any other packing material of a yieldable and refractory nature may be used. The metal layer 2 being of steel has the strength required to support the sheet even though of thin gauge. Moreover, steel enables the prongs 3 struck out from the metal layer, by the apparatus of this invention, to have sucient strength and rigidity to penetrate the packing layers without collapsing when the layersare forced together into intimate contact by a high pressure when making the completed sheet. Instead of three layers, the sheet may be made of a greater number of layers by merely adjusting and arranging those instrumentalities of the apparatus to accommodate the number of layers required for the sheet to be produced.

As shown in Fig. 1, the instrumentalities of the apparatus for producing the composite sheet, are arranged in such order that the prong provided metal layer 2 is produced in advance of the application thereto of the non-metallic layers l. The instrumentality for producing the prong provided metal layer 2 is indicated by 4. The instrumentality for pressing the several layers of the sheet together into intimate contact is marked 5, while the instrumentality for coating the outer sides of the completed sheet with graphite or similar material is marked 6.

Instrumentality d has a pair of horizontally disposed rolls l, 8, power driven and arranged one above the other on shafts 9, IB, as shown in Fig. l. The rolls are geared together for rotation in unison and are made up of alternate cutters Il and spacers l2, as shown in Fig. 5. The cutters Il are in the form of discs, keyed to the respective shafts 9, I0, and havevperipheral portion of the layer making the prong out of the plane of the layer, as shown at a in Fig. e..

As the rotation of the cutter continues inthe direction of the arrow in Fig. 4, the tooth is projected farther through the puncture and finally bends the displaced metal into substantially right angular relation to the layer Completing the formation of the prong, as shown at b in Fig. 4.

At this point, the tooth vleaves the layer, having completed its prong producing operation. The following teeth, each produce a prong, all of which are arranged in a row on the metal layer. rIhe cutters of the upper roll l provide prongs extending below the layer, while the cutters of lthe lower roll 8 produce prongs extending above the layer. Each roll is made up of a multiplicity of cutters, to produce a multiplicity of prongs on opposite sides of the metal layers. rIhis distributes the prongs over practically the entire area of the metal layer and thus provides for an effective connection of the layers together through the prongs.

The metal layer 2 While being acted on by the cutters is supported by the spacers l2, which are also in disc form, being keyed to the respective shafts l, to rotate therewith, The manner in which the spacers l2 support the metal layer 2 is shown in Fig. 6. The cutters are omitted from this figure for the purpose of illustration. The spacers are of such diameter that where their peripheral edges are opposed at the pass between the rolls, there is a space Ill between them to accommodate the metal layer and perxm't its feed 4Q between the rolls. This space is substantially equal to the thickness of the metal layer, so that the latter will not be displaced while being operated upon by the teeth of the cutters. The teeth of the cutters extend beyond the spacers to perforate the layer 2 to produce the prongs 3 thereon. The spacers l2 are wider than the cutters E l so that separated rows of prongs may be produced on the metal layer.' The spacers are provided with peripheral grooves or channels l5 to receive the teeth on the alined cutters ll, as shown in Fig. 5. The walls i6, i6 of the grooves extend to the periphery of the spacers and support the metal layer, as shown in Fig. 6. vWith the teeth on the cutters fitting and lling the grooves l5 on the associated spacers, the inner edges of the walls I6 serve as cutting edges for the cutters to shear and not tearV the metal of the layer 2 along the sides of the prongs in producing the same.

The metal layer 2 in blank or stock form is fed into the space between the rolls fl, 8 from a suitable source of supply located in advance of the rolls, as in roll or reel form, marked Il in Fig. 1. The reel is supported in front of the rolls l, 'Si on bracket arms I8 as shown.

The instrumentality-5 comprises a pair of horizontally disposed pressure rolls i9, 2@ arranged one above the other on shafts 2l, 22, as shown in Fig. l. The prong provided metal layer 2 and the packing layers l, I are fed between these rolls to be pressed together as shown in Fig. 1. Ihe lower roll 2l) is power driven from an electric motor 23 mounted on the base of the instrumentality 5. A belt 24 connects a pulley on the armature shaft of the motor with a pulley 25 at the opposite end of the base of the instrumentality 5. Pulls;r 25 drives a gear pinion 26 which is in constant mesh with a gear wheel 21. Gear wheel 2l drives a pinion 23 whichis in mesh with a gear wheel 2S Xed to the shaft 22 of lower roll 20. Upper roll i9 by means of vertical guide-ways Sil in standards '3l at the sides of instrumentality 5 may be set by screws 32 to furnish the pressure desired to press the layers together on passing between the rolls.

The packing layers l, i are fed to rolls i9, 23 on opposite sides ofthe prong provided metal layer 2 from a suitable source of supply, as for example, rolls or reels 33, 3. of such material supported for rotation in a frame work 35 located between instrumentalities l andl 5 as shown in Fig. l. The perforated metal layer 2 is passed between reels 33, 34 so that the other layers l may be fed to the rolls I9, 20 on opposite sides of the metal layer. The several layers are collected and guided to the pass between rolls i9, 2@ by axture 36, which as shown in Fig. 2, is divided into three passage-ways 3l, 38 and 39. The latter are arranged one above the other and guide the layers l, 2 to the rolls, yet keeping the layers separated and apartuntil they reach the bite of the rolls. With the layers kept apart, they may individually weave and stretch, without one interfering with the other as pressure is exerted on the layers to unite them at the rolls i9, 2t. Considerable pressure is exerted on the layers as they pass between the rolls to bind them tightly together by intimate contact and to also imbed the prongs on the metal layer well in the packing layers. Under this high pressure the outer ends of the prongs are bent over slightly to clinch the packing layers l to the metal layer 2, as indicated at c in Fig. 3.

The pressing and clinching action described occurs continuously as the several layers making up the sheet are passed between the rolls i9, Eil. Due to the fact that the lower roll 2i) is power driven and the rolls press the several layers together with considerable pressure, the layers are drawn into the space between the rolls by the frictional feed on such layers. Moreover, this feed passes the completed sheet beyond the instrumentality 5 to the instrumentality E where the sheet is coated on opposite sides with graphite or other paint to prevent the sheet from sticking or adhering to similar sheets or to the surfaces of the members between which the sheet in packing or gasket form is clamped.

Instrumentality -6. comprises a housing i0 throughwhich the composite sheet is fed "and contains nozzles or sprays 4I, 4l to coat the opposite sides of the sheet with graphite or the like.

The compositesheet passes from the spraying device 6 either'to a. winding apparatus on which the sheet is wound into roll or reel form for future use or to an automatic press for blanking or cutting gaskets from the composite sheet. The winding device would include a clutch of a character to'compens'ate for the variations in the size of the roll as the material is reeled.

The rolls 1, 8 of the instrumentality 4 are geared or otherwise connected to the main drive of the entire apparatus in order that the feed of the several layers through the machine will be uniform, and thus prevent the movement of one layerata speed diiferent from that 'of another.

' The apparatus shown and described enables the entire composite sheet to be madeI in one continuous and uninterrupted operation, with the sheet either wound into reel form or fed directly into the blanking machine with which the apparatus is usable.

To strip the perforated metal layer 2 from the teeth of the cutters I I, there are provided strippers 62, d2 arranged in sets above and below the metal layer on the delivery side of the rolls 1, 8, as shown in Fig. 4. The strippers are disposed between the cutters II and curved edges 43 conforming to and iitting against the peripheral edges of the associated spacers I2, as indicated in Fig. 4. The strippers are shaped as in Fig. 9, and have end portions M which project into the space between the rolls 'I, 8, and guide the metal layer therefrom as the teeth leave the same. With a stripper 42 at each spacer, it is necessary to provide the end portion 44 of each spacer with a slot 45 to receive the teeth on the cutter cooperating with such spacer.

Should it be desired to make a composite sheet with a metal layer on the outer side of a nonmetallic layer such as may be required for some forms of packing and gaskets, it is needed only to replace the cutting discs of one roll with spacer 25 discs and allow the sheet to be perforated by the in staggered relation to the prongs of an adjacent row or rows, the cutters are set on their shafts 9, I 0, with one cutter about one half tooth ahead of the other. Each spacer l2 instead of being in one piece, as shown in the drawings, could be made up of three pieces. In this event, two pieces would form the walls I'B, I6 and the third piece would form the bottom of the groove I5.

When making a composite sheet of more than three layers, the feed to the pressure rolls I9, 20, will be as in Fig. l0, with a suitable separator and guide fixture or means for the various layers in advance of the rolls. In Fig. 10, the sheet being formed, comprises 5 layers, three packing or asbestos layers Ia, Ia, and two metal layers 2a, 2a. These layers are arranged with packing layers on opposite sides of each metal layer. The packing layers are-fed from rolls d to h, the rolls c and g being of prong provided metal layers.

The apparatus of this invention is simple and eiective in operation and enables composite sheets of the character described to be readily and easily made.

The details of construction and arrangement of parts shown and described may be variously changed and modified without departing from the spirit and scope of this invention, except as pointed out in the appended claim.

What is claimed is:

In an apparatus for deforming a plane sheet of mate-rial by tearing portions thereof out of the plane of said sheet to form spaced prongs projecting from opposite sides thereof, a pair of rollers having rows of prong forming devices thereon, and means for stripping the sheet from said rollers, said stripping means comprising a i 

